Projects
Below are a few projects I have worked on showcasing my ability to find creative, effective designs to solve a variety of problems. Specifically showcased are my skills in design, CAD, and rendering of prototypes.
Bracket Design
01
Overview
For this project, I was tasked with creating a mounting bracket for a router spindle. Within the given design space my goal was to minimize deflection.
02
Topology Optimization
In order to develop an efficient solution, I used topology optimization through nTop to solve for the Z-Axis loading case.
03
Modeling
Based on the topology optimization results the bracket required maximization of strength at the boundaries, in order to maximize torsional rigidity.
04
FEA
To validate the bracket, I ran FEA in NX to determine the maximum deflection under each load case.
EV Powertrain Model
01
EV Transition
In 2022, Northwestern Formula Racing transitioned from an IC powertrain to EV. In order to enable this transition, I built a power model of our new powertrain.
02
Characterization
Based on published data for our batteries, inverter, and motor I constructed datasets for key characteristics. Using Matlab I fit curves to the data in order to derive equations for each characteristic.
03
Simulation
To obtain data from a "real" driving environment, I simulated the vehicle over a full endurance run, as it would see at competition, using OptimumLap.
04
Modeling
Using Excel, I combined the simulation data and characterization data to create a model which predicted voltage, current, power, and heat generation for the accumulator, inverter, and motor.
Compressor Wheels
01
Compressor Wheels
In order to enable a new product rollout, I was tasked with creating Go-No Go gauges for a number of turbocharger compressor wheels.
02
Measurement/Modeling
With lacking manufacturer drawings, I began by collecting measurements of the wheels using an optical comparator. Using these measurements I built a CAD model for each wheel.
03
Additive Manufacturing
To test the designs, I used a resin 3D printer to create prototypes. Achieving .1mm tolerances through 3D printing required precise settings and calibration.
04
Final Part
The final part was machined from A2 tool steel and deployed to the manufacturing line.
Additional
01
Spinal Sense
Working with doctors from the Shirley Ryan Ability Lab, I worked with a team to develop a spinal cord model enabling better patient education.
02
Steering Wheel
Using FEA, 3D scanning, and additive manufacturing, I was able to develop a more ergonomic wheel for NU's formula team while achieving 30% weight savings.
03
Testing Rig
In order to speed repeated testing of position sensors, I designed an automated testing rig assembly in Solidworks as well as an electronics schematic.
04
ICE Tuning
Starting from scratch, I developed a base map and did all tuning for Northwestern Formula Racing's Yamaha R6 engine on a MoTeC M130 ECU. This lead to a 15% increase in our acceleration score.
